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[Hardacrefarm]

Do the two contacts/magnets on the X10 standard door/window sensors actually have to be in contact with each other in order to work properly and reliably?

If not, how far apart is the maximum distance they can be from one another to still perform well?

[Dr.Fiero]

Physical contact isn't needed (nor suggested!).  I'd say keep them within about 10mm or so.

If you've got a meter, just set to ohms, and read across the switch.  Move it in/out, and you'll see the exact trip point (then maybe go 50% of that for safety - false trips suck).